Pemeliharaan Dan Teknik Keandalan IE 184623: Laboratorium Sistem Manufaktur Departemen Teknik Industri - ITS

Pemeliharaan dan Teknik Keandalan
IE 184623
Laboratorium Sistem Manufaktur

Departemen Teknik Industri – ITS
 Gasal 2019
Industrial Engineering ITS

Maintenance management
Pemeliharaan dan Teknik Keandalan

Laboratorium Sistem Manufaktur
Departemen Teknik Industri – ITS
 Gasal 2019

Why study Maintenance ?
• Maintenance has been recognized as the main source for

fulfillment of the production performance.
• However, many organizations have lack of attention on this
activities due to their perspective of thinking that
maintenance is separated from production, have no value
added, and ever cost consume.
• A comprehensive understanding of maintenance
management system has proved that appropriate
maintenance management will provide significant
contributions on productivity improvement trough
improvement the equipment availability and minimize
maintenance cost.
• Therefore, company need to update their knowledge on
maintenance management system in order to gain the
optimal benefit of maintenance activities.
Definition
Maintain
• Cause to continue (oxford)
• Keep in an existing state (Webster)
• Maintain vs modify (change it in someway)
• What is it that we wish to cause to continue?

• what is the existing state that we wish to preserve?
Fact : every physical asset is put into service because someone

wants it to do something, to fulfill a specific function.
When we maintain an asset, we wish to preserve which it continue
to do whatever its user want it to do.
Definition (2)
Maintenance :
• all actions necessary for retaining an item in, or restoring it
to, a specified condition (MIL-STD 721 B)
• ensuring that physical assets continue to do what their
users want them to do
Maintainability :
• the measure of the ability of an item to be retain in or
restored to specific condition when maintenance is
performed by personnel having specified skill levels, using
predescribed procedures and resources, at prespecified
level of maintenance and repair (MIL-STD 721 B)
• the probability that a failed unit is put back to satisfactory,
operable condition in a given down time
All the study on maintenance of system or component always
considering and based on system’s or component’s reliability.
Definition (3)
Reliability :
• the probability that a unit will function normally when used
according to specified condition for at least a stated period
of time.
• The probability of an item performing its required function
for the intended period of time [0,t]
Availability :
• The probability that an item is operating at a specified time
t, depend on mean up time and mean down time
Maintenance Scope
Primary function of maintenance is to control the condition of equipment,

there are some problems associated with:
1. reliability considerations
2. inspection : frequencies and depth of activities
3. Preventive Maintenance and overhaul interval
4. Repair or Replace
5. replacement rule for component and capital equipment
(taking account of technological change)
6. maintenance crew sizes
7. composition of machines in a workshop
8. spare provisioning rule
9. Maintenance project scheduling (sequence rule for jobs,
start time for constituent jobs)
HISTORY OF MAINTENANCE
FROM MOUBRAY (1997)

Change due to
Maintenance has changed – due to

 huge increase in the number and variety of physical asset
(plant, equipment, and building), more complex design,
 new maintenance techniques
 changing view on maintenance organization and
responsibilities.
 Respond to changing expectation
 Rapidly growing awareness that equipment failure affect
safety and the environment
 growing awareness of the connection between
maintenance and product quality
 increasing pressure to achieve high plant availability and to
contain cost
Generation
since 1930, the evolution of maintenance can be traced through three

generation :
A. the first generation (covers the period up to worldwar II)

 the industry was not very highly mechanized –
downtime did not matter
 most equipment was simple – reliable and easy to repair
 no need for systematic maintenance of any sort beyond
simple cleaning, servicing, and lubrication routine.
 The need for skill was lower
Generation
B. the second generation

 wartime pressure – increase demand for all kinds while the
supply drooped sharply- increase mechanization
 1950 – all type machine more numerous and more complex –
industry was beginning to depend on them
 downtime came into sharper focus – the idea that equipment
failure could and should be prevented – led to the concept of
preventive maintenance
 cost maintenance also started to rise sharply relative to the
other operating cost - led to the growth of maintenance and
planning and control systems
 a sharp increase in the cost of capital as fixed assets – led to
start seeking in which they could maximize the life of the
assets.
C. the third generation
 mid seventies – the process of change in industry on new
expectations, new research, and new techniques
new expectation
 Downtime affect:
 reducing output
 increasing operating cost
 affecting customer service
 greater automation – more and more failure affect
 the ability to sustain satisfactory quality standard
 have serious safety or environment consequency
 cost of maintenance still rising – become the highest or
second highest element of operating cost
new research
 connecting between operating age and failure
new techniques, new development include:

 decision support tools : hazard studies, expert system, FMEA
 new maintenance technique: conditioning monitoring (PdM)
 designing equipment emphasis on reliability and maintainability
 a major shift in organizational thinking: participating, team working,
flexibility
 right choice of techniques : to improve assets performance, and reduce
cost of maintenance
MAINTENANCE SYSTEM

Maintenance and other function
Interaksi
Interaksi antara fungsi maintenance dengan keputusan lain menunjukkan

adanya area potensial konflik yang dapat diselesaikan dengan beberapa
trade off :
1. Pada jangka pendek

a. Trade off antara maintenance dengan scheduling.
Minimum repair time dengan interupsi preventive
maintenance vs operation time yang panjang unt
mengoptimalkan completion time shg dapat meningkatkan
frekuensi brakedown
b. Trade off antara maintenance dengan aggregate

planning.
Decoupling inventory spy PM ebih mudah dan murah vs
integrasi inventory unt perencanaan minimasi ongkos produksi
Keterangan
2. Pada jangka panjang
a. Trade off antara maintenance dengan QC.

Optimum spacing PM vs diijinkannya deteriorasi
dalam kualitas output suatu proses
a. Trade off antara maintenance dengan desain sistem
(kebutuhan maintenance crew).
Keseimbangan antara biaya crew time yang idle dan
waiting time peralatan yang direpair vs job
description dari crew pada saat idle.
Maintenance sebagai suatu sistem
Decisions Variables
What to maintain ?
 Fasilitas produksi, mesin, gedung, sistem manusia mesin, dll

 Memilih item mana yang akan di maintain
 Item dikelompokkan berdasarkan :
 kontribusinya thd overall reliability dan
 pengaruhnya thd total biaya operasi.
 Tingkat pengaruh dapat diukur dengan total biaya repair
dan downtime dikombinasikan dengan biaya keterlambatan
pengiriman
Memilih item : ABC analysis
• A: critical components : jika fail

menyebabkan sistem produksi
terganggu, biaya breakdown
repair tinggi, lost production
akibat downtime --- butuh kontrol
ketat dan aktivitas maintenance
yang intensif
• B : major component : yang
menentukan performansi sistem
tapi jika fail maka produksi tidak
harus berhenti --- butuh aktivitas
dan control maintenance yang
moderate
• C : minor component : supportive
element jika fail tidak akan
mengganggu operasi --- aktivitas
maintenance yang terbatas atau
tidak formal
Memilih item : ABC analysis
• ABC analysis untuk

reliability dapat
digunakan sesuai
dengan level organisasi
dan karakteristik
komponen (ukuran,
kompleksitas, dan
interdependensi)
• Option maintenance
untuk continuous
process < flow shop <
job shop
Decisions Variables
• Siapa yang melakukan maintenance ? Internal / eksternal

• Bagaimana maintenance harus dilakukan ?
– Alternative untuk memaintain alat dengan biaya
minimum
– Inspeksi, corrective maintenance / repair, PM ?
• Dimana aktivitas maintenance dilakukan ? Centralized atau
decentralized
Output sistem maintenance
1. Jadual pelaksanaan kebijakan yang terpilih

a. Inspeksi : menaksir status peralatan dan fasilitas
b. Repair ketika breakdown terjadi, spesifikasi prioritas
dan persyaratan skill, part, dll
c. PM kapan layak dilakukan
2. Laporan
a. Status peralatan setelah inspeksi, repair, atau PM
b. Proyeksi kebutuhan spara part dan decoupling
inventory untuk pekerjaan maintenance yang sudah
dijadualkan
c. Proyeksi kebutuhan kapasitas maintenance yaitu skill
dan jam kerja yang dibutuhkan
Jumlah output yang dihasilkan tergantung pada kualitas
sistem informasi yang sekarang ada.
Pengembangan kebijakan maintenance yang baik
membutuhkan penggunaan sistem informasi
terkomputerisasi (CMMS).
Input sistem maintenance
• Input yang berupa informasi dibutuhkan

untuk menentukan kebijakan maintenance
yang paling tepat – merupakan input bagi
sistem pengambilan keputusan
maintenance
• tenaga kerja, spare part, peralatan khusus
untuk uji dan repair – diperlukan untuk
melakukan kegiatan maintenance
• Input informasi berupa history komponen
(operating time, repair yang dibutuhkan),
spare part cost dan labor cost, efek
downtime pada production lost dan/atau
delay.
Input sistem maintenance

Konstrain sistem maintenance
1. Desain sistem produksi (teknologi proses, layout,

kapasitas / crew size)
2. Aggregate planning dan keputusan capital
budgeting (allowance untuk menlakukan
decoupling inventory akan mempengaruhi
tingkat dependensi antar stage yang berurutan
dan fluktuasi jumlah maintenance crew
Kriteria performansi sistem maintenance
• Maintenance berfungsi untuk menjaga operasi sistem

produksi supaya ekonomis dan lancar
• Pemilihan kebijakan optimal dibuat berdasarkan alternatif
breakdown / corrective dan PM
• Kriteria performansi menjadi dasar penentuan keputusan
maintenance optimal

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Laboratorium Sistem Manufaktur

Industrial Engineering ITS